Shanghai Jiale Co., Ltd. Project Case: Energy-Saving Application of Air-Suspension Blowers in the Textile Printing and Dyeing Industry

Introduction: The textile printing and dyeing industry’s wastewater aeration systems have long faced persistent challenges, including high energy consumption, complex operation and maintenance, significant noise, and risks of oil‑contaminant pollution—making them a critical focus for enterprises seeking to reduce costs, improve energy efficiency, and achieve green transformation. This paper takes the Shanghai Jiale Co., Ltd. aeration system upgrade project as a practical case study. Drawing on on‑site photographs and measured operational data, it provides an in-depth analysis of how the AVIC Huaqiang air‑suspension high‑speed centrifugal blower—leveraging core technologies such as air‑suspension bearings and high‑speed permanent‑magnet variable‑frequency drives—overcomes the operational shortcomings of conventional Roots blowers, delivering clear application advantages. Project implementation demonstrates that this equipment can achieve… Over 40% energy savings, significant cost and maintenance reductions, low noise and oil-free operation, and low-carbon emissions reduction. Its multiple benefits provide a replicable, actionable benchmark solution for energy‑efficient upgrades of wastewater treatment plants in the textile printing and dyeing industry, supporting the implementation of the “dual carbon” strategy.

I. Project Background

As a traditional industry characterized by high energy consumption and substantial emissions, the textile printing and dyeing sector encompasses numerous production stages—including weaving, dyeing and finishing, printing, and washing—and its associated wastewater treatment system represents a core component of the facility’s overall energy footprint. Currently, the industry predominantly employs a wastewater treatment process comprising pretreatment, biochemical treatment, and advanced tertiary treatment. Among these, the aeration‑blowing system in the biochemical stage is the primary energy‑intensive unit, accounting for 50% to 70% of the entire wastewater treatment plant’s electricity consumption, and is widely recognized as a major power consumer in printing and dyeing enterprises.

For a long time, the vast majority of domestic textile printing and dyeing enterprises have relied on conventional Roots blowers as their core aeration equipment. However, this equipment suffers from numerous industry‑specific shortcomings: high energy consumption during operation, a limited and single‑mode variable‑frequency speed control, and a narrow range for regulating air volume and pressure—making it ill‑suited to meet the intermittent, load‑varying gas‑demand requirements of printing and dyeing production lines. Moreover, the equipment contains many wear‑prone components, such as gears and bearings, necessitating frequent replacement of lubricants and seals, which leads to high maintenance frequency and elevated overall operating costs. In addition, its substantial operational noise and the risk of oil‑contaminant leakage not only drive up production and operational expenses but also hinder the green and standardized upgrading of factory premises.

Shanghai Jiale Co., Ltd. was established in 1993 and is located in Jinshan District, Shanghai. It is a leading enterprise in the textile printing and dyeing industry, integrating fabric R&D, weaving, dyeing and finishing, printing and embroidery, and ready‑made garment processing into a fully integrated industrial chain. Against the backdrop of the national “dual carbon” strategy and the broader shift toward green, low‑carbon industrial transformation, and in response to steadily rising electricity costs, stringent environmental emission standards, and the need to enhance plant productivity and efficiency, the company has actively promoted energy‑saving technological upgrades to its production equipment and introduced… AVIC Huaqiang Air-Suspension High-Speed Centrifugal Blower , a comprehensive upgrade and retrofit of the biochemical aeration system for dyeing and finishing wastewater at the plant site was carried out. Following commissioning, the system has demonstrated stable operation and remarkable performance, successfully achieving multiple objectives—energy savings and cost reduction, noise mitigation and quality improvement, and low‑carbon environmental protection—thereby setting a benchmark for green upgrades of aeration systems in the textile dyeing and finishing industry.

II. Core Technological Advantages of the Equipment

AVIC Huaqiang is a high-tech enterprise specializing in the R&D, manufacturing, and sales of air‑suspension energy‑saving equipment. Leveraging an industrial layout that integrates “Shanghai R&D + Guiyang Manufacturing,” the company has been deeply engaged in the industrial energy‑efficient ventilation sector for many years. Its air‑suspension high‑speed centrifugal blowers revolutionize conventional fan designs by eliminating redundant components such as speed‑increasing gears, couplings, lubrication systems, and cooling fans. By relying on three core technologies, the products achieve distinctive competitive advantages and are highly suited to the textile and dyeing industries’ demanding operating conditions—characterized by high humidity, stringent cleanliness requirements, variable operating parameters, and stringent environmental standards.

1. Air‑suspension bearing, operating with zero oil and zero friction.

The equipment employs aerospace‑grade air‑bearing technology, ensuring zero mechanical contact and negligible frictional losses during operation, thereby eliminating the need for a lubrication oil system. This thoroughly addresses common issues with conventional Roots blowers—such as lubricant emulsification and seal degradation leading to oil leakage—while preventing oil contamination from entering dyeing and printing wastewater and causing secondary pollution. It perfectly meets the stringent water‑quality requirements of dyeing and printing wastewater treatment, ensuring stable compliance of the treatment system, and significantly reduces maintenance burdens by minimizing the frequency of lubricant‑related consumable replacements.

2. High-speed permanent-magnet synchronous motor, with industry-leading energy efficiency rating.

Equipped with a high-efficiency permanent‑magnet synchronous motor, it achieves a maximum speed of 200,000 rpm and boasts an efficiency exceeding 97%, significantly surpassing the energy‑efficiency standards for conventional fan motors. With no mechanical friction losses, it delivers efficient and stable power output, reducing unnecessary energy consumption at the core drive level and laying a solid technological foundation for exceptionally high energy savings.

3. Three‑dimensional flow impeller + intelligent variable frequency drive, providing precise air supply on demand.

Equipped with an aerodynamically optimized, high-efficiency three‑dimensional impeller, the system delivers significantly improved aerodynamic heat exchange and air‑delivery efficiency. Paired with an intelligent variable‑frequency control system, it can automatically adjust equipment speed, airflow, and air pressure in real time based on production line capacity, dissolved‑oxygen levels in wastewater tanks, aeration pressure, and other operational data. This addresses the longstanding issues of conventional fixed‑frequency, constant‑speed operation—where excess airflow is vented, leading to energy waste—and precisely accommodates the fluctuating air‑demand conditions typical of the textile dyeing and finishing industry.

4. Miniaturization, long lifespan, and intelligent visualized operations and maintenance

The equipment features a highly integrated design, with a footprint just 1/3 to 1/5 that of conventional Roots blowers, and occupies minimal floor space, making it well-suited for the compact layouts typical of textile printing and dyeing facilities. With a designed service life exceeding 20 years, the unit is equipped with an industrial‑grade smart touch screen that enables real-time monitoring of all key parameters—including pressure, flow rate, power, temperature, and rotational speed—along with data logging and one‑button commissioning, significantly enhancing operational convenience.

III. On-site Measured Operational Data of the Project

Following the completion of this retrofit, the equipment has operated continuously and stably over the long term. Technical personnel monitored and recorded operating data in real time via the on-site MCGS industrial touch screen (actual measurement date: June 28, 2026). The equipment’s operating parameters remain stable, with a high degree of alignment between actual operating conditions and design specifications. Specific data are as follows:

As evidenced by the measured data, under the standard operating conditions for wastewater aeration at the plant site, the equipment’s pressure and flow parameters fully meet production requirements. The unit’s temperature, current, and rotational speed remain stable, with no fluctuations or abnormal operating conditions. Moreover, its ultra‑low operating power underscores exceptional energy‑saving performance, while its adaptability to various operating conditions and operational stability far surpass those of conventional equipment.

IV. Analysis of Energy-Saving and Cost-Reduction Benefits of the Project

1. Significant energy-saving efficiency and outstanding power-saving advantages

Using the conventional Roots blower prior to modification as a benchmark, in… Same air volume: 8.7 Nm³/min; same air pressure: 56.1 kPa. Under standard operating conditions, traditional Roots blowers, constrained by their mechanical design, must maintain an operating power of 18–22 kW, whereas the AVIC Huaqiang air‑suspension blower achieves equivalent aeration performance with only 10.60 kW. According to precise calculations, the comprehensive energy‑saving rate per unit is… Over 40% , fully aligns with the industry’s energy‑saving range of 30%–50% for air‑suspension blowers, delivering industry‑leading energy efficiency.

2. Significant reduction in electricity costs

Textile printing and dyeing enterprises operate on a continuous production model, with fans running for approximately 8,000 hours per year. Based on measured data, the calculations are as follows:

Annual energy savings per unit = (18 kW - 10.60 kW) × 8,000 h = 59200 kWh

Based on an industrial composite electricity tariff of 0.8 yuan/kWh, a single unit of equipment Annual electricity cost savings of RMB 47,360. If the enterprise upgrades its equipment by installing four turbines in line with industry standards, the annual energy savings could exceed 230,000 kWh, resulting in electricity cost reductions of over RMB 180,000 per year. Over the long term, the energy‑saving benefits would be substantial.

3. Operations and maintenance costs have been significantly reduced.

Traditional Roots blowers have numerous wear parts, requiring regular replacement of gear oil, seals, bearings, and other components every three months. Annual consumable costs and labor for maintenance are high, and frequent shutdowns for servicing can disrupt production continuity. In contrast, the AVIC Huaqiang air‑suspension blower features an oil‑free design, eliminates mechanical contact, and employs a gearless transmission architecture with no high‑frequency‑wear components. Routine maintenance is limited to simple cleaning and replacement of the air filter element, eliminating the need for major overhauls or frequent shutdowns. Following the retrofit, the overall operation and maintenance cost of the equipment… Reduce by more than 90% , significantly reducing enterprises’ human and material resource inputs for equipment operation and maintenance.

V. Comprehensive Environmental Protection and Value in Enhancing Production Quality

1. Low-noise operation, optimizing the workplace environment on site.

Traditional Roots blowers rely on gear‑to‑gear transmission, generating operating noise levels exceeding 90 dB. Prolonged operation can lead to significant noise pollution within the plant, adversely affecting the physical and mental well-being of operators. By contrast, the AVIC Huaqiang air‑suspension blower features zero mechanical friction and eliminates gear‑related noise; coupled with an integrated sound‑damping design, its operating noise is kept below 80 dB. This effectively enhances the working environment in wastewater treatment plants and textile‑printing workshops, helping enterprises build standardized, eco‑friendly facilities.

2. Oil-free, clean operation ensures both production and water quality safety.

Wastewater treatment in the textile printing and dyeing industry demands exceptionally high water quality. Conventional oil‑lubricated blowers are prone to seal degradation and oil leakage, which can easily lead to secondary water contamination, compromising both compliance with effluent discharge standards and the quality of finished fabrics. Our equipment operates 100% oil‑free throughout its entire lifecycle, eliminating the risk of oil‑based contamination at the source, ensuring stable, compliant performance of the wastewater treatment system, and mitigating potential oil‑contamination hazards in downstream production processes to safeguard product quality.

3. Low-carbon emissions reduction, supporting the implementation of the dual carbon goals

Energy conservation equals carbon reduction. Based on the national grid’s average carbon emission factor of 0.6101 kg CO₂/kWh, a single piece of equipment that saves 59,200 kWh annually can reduce carbon dioxide emissions by approximately… per year. 36.1 tons If all four pieces of equipment are retrofitted, the enterprise could reduce its annual carbon emissions by more than 144 tonnes, effectively lowering its carbon footprint, supporting it in achieving green‑factory certification and meeting carbon‑reduction targets, and strengthening its competitive edge in green, low‑carbon development.

VI. Project Summary

The energy-saving retrofit project for the aeration system of Shanghai Jiale Co., Ltd.’s dyeing and printing wastewater is a successful case of applying air‑suspended blowers to green technological upgrades in the textile dyeing and printing industry. Measured data from the project fully validate the robust performance of AVIC Huaqiang’s air‑suspended blowers, achieving… Energy conservation, cost reduction, environmental protection, and quality improvement The core values of the Four-in-One approach:

1. Outstanding energy-saving performance: individual equipment achieves an energy-saving rate exceeding 40%, with annual electricity savings of nearly 60,000 kWh, significantly reducing the enterprise’s overall electricity consumption.

2. Cost reduction is substantial: each unit saves over RMB 47,000 annually in electricity costs, and O&M expenses have been cut by more than 90%, continuously helping the enterprise reduce burdens and improve efficiency.

3. Operates stably and reliably, with intelligent variable-frequency drive technology that adapts to the fluctuating operating conditions of textile printing and dyeing processes; all parameters are visualized for streamlined operations and maintenance, enhancing equipment management efficiency.

4. Green value is increasingly prominent: low noise, zero oil contamination, and reduced emissions—comprehensively improving the factory’s production environment and helping enterprises achieve their dual-carbon goals.

At present, the textile printing and dyeing industry is at a critical juncture of capacity upgrading and green transformation. Energy‑saving retrofits of aeration systems represent a key breakthrough for enterprises seeking to reduce costs, boost efficiency, and achieve compliant development. Leveraging its comprehensive advantages—high efficiency, energy savings, maintenance‑free operation, zero emissions, and low noise—the AVIC Huaqiang air‑suspension blower is ideally suited to the production conditions of the textile printing and dyeing sector. It effectively addresses longstanding industry challenges—high energy consumption, complex operations and maintenance, and significant pollution risks—making it the preferred energy‑efficient solution for upgrading aging equipment, building green factories, and advancing dual‑carbon goals. In doing so, it provides robust technological support for the low‑carbon, high‑quality transformation of the textile and light‑industry sectors.